Before Getting Started

PVC is a very common, strong but lightweight plastic used in construction. PVC is a very versatile material. Loved my some, harshly criticized by others. When you think of PVC you probably think of the thin, flimsy, white plumbing pipes you are used to seeing under your kitchen sink. But there are many other variations of PVC that are out there. Without getting into the boring details of it all, there are really only a few viable options you have when it comes to making your own quality Portable Horse Corral at home.
Keep in mind the absolute most important aspect when choosing a PVC material:  UV & Sunlight Resistance.

Choosing Materials

First you need to decide on the size of pipe you would like to use for this project. We do not recommend using anything under 3/4" or anything over 1 1/2" in diameter. However, even 1 1/2" diameter pipe is a bit overkill. 1 1/4" pipe will do perfectly fine if you are wanting a more heavy duty panel.  On the other hand, 3/4" pipe will give you an ultra lightweight panel. So you need to consider what will work best for you and your horse's needs. For example, ask yourself; Is your horse extra pushy on fencing? Maybe you need to make heavy duty panels or maybe you need to add electric to the panels or perhaps both?
​Now to choose the type of pipe you want:​

PVC Pipe

Option 1: Furniture Grade PVC pipe (Ideal)
  • This is rated for being High impact resistant as well as UV resistant. Meaning it is meant to be outside in the harsh elements without becoming brittle and is able to take a beating without breaking.
  • Think lawn furniture or children's playhouses. 
  • It's super smooth with a shiny finish. Comes in White and many other fun colors too (see pic to the right).
  • This is obviously the best material for making a high quality, super durable portable horse corral. The downside, is that this pipe is incredibly expensive and is essentially a special order item (i.e. it can't be found in the store). Which means you have to have it shipped to you and pay an arm and a leg in freight costs.​
Option 2: Utility Grade PVC pipe (Recommended)
  • This is rated for many types of uses around construction sites. It can hold up to many more variables including, but not limited to, direct sun exposure. This is the most important aspect you need when choosing the type of pipe you use to build your own Portable Horse Corral. ​
  • This is the second best material you can choose when building your Portable Horse Corral because it is UV and Sunlight resistant. Plus is has a bell end that can be used for the legs of your panels, which helps add stability. This type of PVC pipe can be found in any hardware or home improvement store​. 
Option 3: White Plumbing PVC pipe (Not Recommended)
  • ​​This is rated for residential uses and is used for high pressure water lines.  Can be found in any hardware store.​
  • Not UV resistant which means after being exposed to sunlight for prolonged periods, it will burn, become brittle, cracked and overall not a safe option when choosing a material to build your Portable Horse Corral.
  • The pictures to the right show you what white plumbing PVC will look like after sunlight exposure. It becomes burned, brittle and will eventually break. Not an ideal, safe or money-saving option for Portable Horse Corral panels. 
  • The only way to be able to safely use white plumbing PVC pipe, is to paint it with some UV resistant, plastic only paint. You have to make sure you get the right type of paint, or the pipe could still be compromised when exposed to sunlight. The problem with using this type of PVC pipe, is that it is very labor intensive. There is no great way of painting PVC pipe and being done with it. You will need to use many, many coats of paint to get a decent layer on the pipe and even then, the paint will still scratch and chip off when you use it. So as you use it, the panels will rub together, your horse will rub on them etc and the paint will scratch and chip off the pipe. As this happens, you will need to continuously re-paint over the spots that are scratched or risk the pipe getting burned by the sun and thus compromising the strength and safety of your corral. 
  • All in all, you will be spending A LOT of your time painting and re-painting these Corral Panels if you decide to go with the White Plumbing PVC pipe option. This is not really a time or money-saving option in the long run.​​​​

PVC Pipe Fittings

Now that you have chosen the best type of PVC pipe, you will need to consider the PVC pipe fittings. Fittings are the "joints" you use to connect all the pieces of pipe together to form your Portable Horse Corral. Depending on the corral style you want to build, there are 3 fitting types you will need to consider; Elbows, Tees and Crosses. You have very similar options available for PVC pipe fittings as you do for the PVC pipe on its own. ​​
Option 1: Furniture Grade PVC fittings (Ideal)
  • This is rated for being High impact resistant as well as UV resistant. Meaning it is meant to be outside in the harsh elements without becoming brittle and is able to take a beating without breaking. 
  • Think lawn furniture or children's playhouses. ​
  • It's super smooth with a shiny finish. Comes in White and many other fun colors too (see pic to the right).
  • This is obviously the best material for making a high quality, super durable portable horse corral. Unlike with the Furniture Grade PVC pipe options, these are actually much more cost effective and easier to get ahold of. You won't have to paint these in order to use them safely. This is the ideal option and you can easily purchase those online HERE.
Option 2: Utility Grade PVC fittings (Unviable)
  • ​These do exist, but not in the molds needed for building a Portable Horse Corral. So this is not a viable option. ​
Option 3: White Plumbing PVC fittings (Not Recommended)
  • This is rated for residential uses and is used for high pressure water lines. 
  • Not UV resistant which means after being exposed to sunlight for prolonged periods, it will burn, become brittle, cracked and overall not a safe option when choosing a material to build your Portable Horse Corral. ​
  • You can see from the pictures how it looks before use and after it has been used and exposed to sunlight. The fitting below broke and cracked after being exposed to sunlight. Not a good option. 
  • The only way to be able to safely use white plumbing PVC fittings, is to paint it with some UV resistant, plastic only paint. You have to make sure you get the right type of paint, or the fittings could still be compromised when exposed to sunlight. The problem with using these types of PVC fittings, is that it is very labor intensive. There is no great way of painting PVC fittings and being done with it. You will need to use many, many coats of paint to get a decent layer on the fittings (which requires a lot of time to paint; let it dry; paint again and so on) and even then, the paint will still scratch and chip off when you use it. So as you use it, the panels will rub together, your horse will rub on them etc and the paint will scratch and chip off the pipe. As this happens, you will need to continuously re-paint over the spots that are scratched or risk the pipe getting burned by the sun and thus compromising the strength and safety of your corral. 
  • All in all, you will be spending A LOT of your time painting and re-painting these Corral Panels if you decide to go with the White Plumbing PVC pipe option. This is not really a time or money-saving option in the long run. So keep that in mind when making your choices. ​​

PVC Pipe Size

Now that you have selected your material type. You need to pick a size. This really depends on your horse and what your intended use for the panels is. Cost could also be a factor for you as well. A smaller gauge pipe is cheaper but would make a lighter panel. So if your horse needs something heavier, then you may need to go with a bigger gauge pipe. This however, would make a heavier panel overall which might be better for your horse but may be more difficult for you to maneuver and set up on your own (if that is a contributing factor). In which case, you could always go with the smaller gauge pipe, but add electric wire to the panel. That way it is still super lightweight for you to move and takes up less space while storing AND you still get the extra security your pushy horse needs to be contained. Finally, you may want to make your panels out of a heavy gauge pipe AND add electric for extra security. We have only done this option one time for a customer who had an 18hh stud horse.

Here are some questions you need to ask yourself and consider before choosing the size of pipe you need:
  • Does my horse respect fencing? ​
  • Do they push and rub themselves against it to scratch themselves?
  • Do they hit the fence because they are lunging and being aggressive towards other horses? 
  • How often will I be using the panels?
    • ​Consider how often you will be having to set them up, take them down, put them in and out of storage, either at home or in your trailer. 


you need to decide how many panels you would like to make for your Portable Horse Corral. You will need 30 feet of pipe per panel. That is three 10ft lengths of pipe per panel. So if you are making 8 panels you will need to get 24, 10ft lengths of pipe. If you are making 10 panels you will need to get 30, 10ft lengths of pipe. ​
Next you will need to cut the pipe to the proper length for your desired corral panel style. For this tutorial we will be making 3 rail panels. They will be 5ft in length and a little over 4ft tall. You can of course modify the measurements to fit whatever panel style you like and that works best for your horse. For simplicity sake, we will be making the panels to the above measurements. ​

Safety Precautions

Cutting the PVC Pipe- Every method to cut PVC pipe involves tools that use a blade. Each of these tools can cause serious harm if not used properly. Be sure to read, understand and follow all the safety measures that come with your tools. Failure to do so could cause serious harm.
  • Hands- Always be aware of where your hands are when cutting PVC pipe. Be sure to use a clamp to hold the pipe, not your hands, when cutting.
  • Eyes- Wear safety glasses or goggles while cutting PVC pipe. Tiny shavings and fragments from the pipe can fly around while cutting the pipe. Especially when using power tools.
  • Mouth & Lungs- Wear a mask or respirator. PVC pipe can emit small particles in the air while being cut. These can irritate both the lungs and throat. It’s especially important if you are using a power saw, which can heat up the pipe. PVC when heated to a melting point can emit chlorine gas, which with long-term exposure, can be dangerous.
Gluing- Make sure to be in a well-ventilated area while gluing and assembling your corral panels. The chemicals and fumes from the glue can make you nauseous, dizzy or lightheaded. They are also flammable and can cause a fire. So, do not smoke around your project or expose the glue to any source of flame or spark while assembling.
 Tools:
Listed here are some types of tools you can use to cut your own pipe.  Keep in mind that any hand tool used for cutting will be easier to make cutting mistakes and may not always cut the pipe evenly or smooth. Be sure to read and understand how to use any cutting tool you use in order to make sure you can make even and smooth cuts. There also may be fraying of the plastic, especially with a handsaw. Also, keep in mind how many pipes you will be cutting. 
  • Hack Saw/Back Saw- This is a very common tool to cut PVC pipe. However, it can be time consuming to use and can be difficult to make straight and even cuts with unless you have a miter box.
  • Scissor-Style Pipe Cutter- Inexpensive and fairly easy to use. However, they can be limited in their cutting ability and can cause stress to the hands after a lot of cutting. These should really only be used on 1” sized pipe or smaller
  • Ratchet-Style Pipe Cutter- This tool is slightly more expensive than the scissor-style pipe cutter, however you can cut large PVC pipe more easily. You can cut up to 1 ½” pipe with this type of tool in some cases. This tool can cause stress to your hands after using for a while.
  • Power-Miter Saw- This type of tool is the most ideal way to cut a larger quantity of pipe. However, unless you already own one of have access to one, they can be expensive.  
-If you do not own or have access to any of these types of tools AND/OR do not wish to purchase one, then you can always have someone who works at your hardware store of choice cut your pipe for you (for an extra fee). They will have a power saw they can use. The extra fee really depends on the hardware store, so be sure to ask about that in advance. Simply tell them the size cuts you need for each pipe and they can prepare that for you.
- If you do decide to purchase one of the types of tools above, they are available in your hardware store. But be sure to discuss the type of project you are doing with someone who works at the hardware store. They will be able to help you choose the best type of tool for the job. They can also help you understand how to use it as well.

More Info On Tools:
  • Be sure you are using the right tool for the job. Tools that are used exclusively for cutting wood are not recommended since PVC and wood have different characteristics. You can talk to someone who works at your hardware store to help you with picking out the right tool.
  • If you are using a power tool, be sure to clamp the PVC down. This is for safety. It is also not recommended that you use any power tool where the user has to move the pipe INTO the blade. Meaning the blade is fixed. This has to potential of making mistakes while cutting the pipe and can also lead to serious harm if not used properly. Be sure to read and fully understand all safety manuals that come with any tool you purchase; power or hand tools alike.
  • Handsaws that are meant for wood are also not recommended since those types of saws have a wider, thicker blade, which will make less precise cuts. Hacksaws have a thinner blade and will make a more precise cut.

Making The Cuts

For each panel you will need the following pieces of PVC pipe and PVC pipe fittings:
  • (3) 18" pieces of PVC pipe
  • (6) 15" pieces of PVC pipe
  • (6) 28" pieces of PVC pipe
  • (2) PVC Elbow fittings
  • (5) PVC Tee fittings 
  • (1) PVC Cross fitting
​You will make the following cuts on each 10' stick of PVC pipe. They typically come in 10' lengths. If you are using the Utility Grade PVC pipe (electrical conduit PVC), then one end of each 10' stick, will have a bell end and the other will be a straight end. We recommend using the bell ends as your leg pieces, otherwise they will be useless for the project. If you are using Furniture Grade PVC pipe or White Plumbing PVC pipe, both ends of those will be straight and it doesn't matter which end you start making your cuts. For simplicity sake, we will show you how to make the cuts using the Utility Grade PVC pipe. If you didn't get that type of PVC pipe for this project, then you will still make the same cuts, but it doesn't matter which end you start with. 
The black lines indicate where you should cut and each section is labeled with what it should be measured to. The great thing about PVC is you can use a sharpie or other marker to mark out the measurements for the whole pipe before cutting. This is what we recommend doing on all the pipes before you start the cutting. But you can also just do it for one 10' stick of PVC pipe and see how it goes and make any needed adjustments before moving on to the rest of your pipe cutting. 

For every 10' Stick of PVC pipe you cut, you will have the following pieces:
  • (1) 18" pieces of PVC pipe
  • (2) 15" pieces of PVC pipe
  • (2) 28" pieces of PVC pipe​
So be sure to calculate how much pipe you need to make your panels. The amount of 10' sticks of PVC pipe you get will depend on how many panels you would like to make for your corral set. No matter how many panels you are making for your Portable Horse Corral set, you will be using three full 10' sticks of PVC pipe per panel. For example, for 8 panels you will need to purchase and cut 24 of the above picture to make those 8 panels. If you are making 10 panels, you will need to purchase and cut 30 of the above picture and so on. The best part about this Corral Panel design is that every single 10' length of pipe will be cut as shown above. Some other designs require a bit more complicated sorting and cutting than this one. 

Assembly

Make sure you are working outside or in a well-ventilated area. PVC glue has very strong fumes and can make you feel dizzy or ill. Therefore we recommend using a mask. To make assembling your panels easier, we recommend that you use a large table or otherwise flat surface. It makes it easier to line up your pipe fittings. Some people have also suggested that using a rubber mallet can help get some stubborn fittings onto the pipe. But it isn't mandatory.

​Each Panel Requires:
  • 3 bell legs
  • 6 short pieces
  • 6 long pieces
  • 2 elbow fittings
  • 6 tee fittings
  • 2 cross fittings
Example of a Finished 3 Rail Panel

Gluing Tips to Consider Before Assembling

There's no right or wrong method to assemble these panels unless you glue the fittings into the wrong piece of pipe. So we highly recommend that you start by assembling one panel without any glue. This will give you a good idea of the best method that works for you and if there are any areas that you might find more challenging before you add glue to the mix. PVC glue can dry very quickly in some scenarios which might make it even more challenging to assemble your panel if you don't know exactly what you are doing and now have to race against the clock of your glue drying before you get the pipe fully into the fittings all the way OR if the fitting is slightly crooked and now the glue is completely dry and there's nothing you can do about it. So assemble a panel for practice before you use glue and you should be on the path to success. 
​
Gluing Tip 1: 
Make sure you apply the glue to the inside of the fitting as well as the outside of the pipe in the area that you are about to insert into the fitting. This will create a cement-like bond and make your panels secure and safe! If you do not get a really good and even coat of glue on the inside of the fitting AND the outside of the pipe, then there is a very high likelihood your panel will come apart, and probably not at a good time either. It will come apart while you're hundreds of miles from home, with no hardware store in sight. If you're at all paranoid about this, just keep a small can of glue in your trailer for when you travel. 
Gluing Tip 2: The glue acts as a lubricant and makes it easier to get the pipe inside the pipe fittings. So if you were having a tough time assembling your corral without glue, you’ll find it much easier to assemble with the glue. Again, please assemble a panel without glue first to help you avoid mistakes when you do use the glue. 
Gluing Tip 3: The glue can dry very quickly. Especially if it's really breezy or you have a fan blowing on you while you are working. So if you only put a thin layer of glue on both pieces, then the glue may be dried before you can assemble the pieces. Something to keep in mind is that the more glue you use, the longer it takes to dry. So this might be helpful while you assemble your first few panels. This will give you a couple more minutes to straighten anything that is crooked or to pull something apart that you accidentally put together. If you find that glue is dripping all over when you assemble your pieces, however, then you know you are using too much glue. Not only is this a bit wasteful but it is very messy too. It can stain any clothing you are wearing, the table or area you're working on and it can also drip all over your panel. While this doesn't affect the integrity of your panel, it does make it look unsightly and can cause other things to stick to your panel. You’ll have to find what works best for you. When pieces are glued together, they typically take no more than 2 minutes to fully dry and set in place and if you didn't use enough glue, it can dry even faster (like in 30 seconds). 

Okay, Finally Assembling The Panels

1.   Gather all materials needed for 1 panel. Listed above.
2.   Make the leg pieces first. Glue a short piece to an elbow fitting. Then glue a tee fitting to the other end of the same short piece. Make sure that the open end of the elbow is lined up with the open end of the tee so that the panel is not crooked. This is where a table comes in handy. You can lay out the 3 fittings on the table as shown, and then insert the pipes where needed. 
3.   Repeat Step 2 to make the second leg piece. It will look identical to the first one. 
4.   Now you will make the middle piece by taking one short piece and glue a tee fitting to one end. Then glue a cross fitting to the other end of the same short piece. Then take another short piece and glue it to the cross fitting. Then take another cross and glue it to the end of that short piece.
5.   Now that you have both leg pieces and the middle piece made you will now start putting them together with the rest of the panel. You will now be taking your "long" pieces of pipe (see reference above), and glue them into the open fittings on one of the leg pieces. There will be one long piece going into the elbow fitting, and one long piece going into each of the tee fittings. 
6.   Glue the middle piece you just made to the three long pieces that are attached to the first leg piece.
7.   Take three long pieces and glue them to the other ends of the tee and cross fittings of the middle piece.
8.   Finally, glue the second leg piece to the long pieces sticking out from the middle piece. ​

Ta Da! You're finished making your first panel! Now that you have a good idea of how to do it, go ahead and repeat these steps to make the rest of the panels in your Portable Horse Corral Set. 
Now, I realize that was a lot of information to absorb and you may feel a bit daunted in building your own Portable Horse Corral. But I promise you, it's actually still pretty easy and you CAN do it yourself! We love when people build these corrals themselves. It's a lot of fun watching people feel empowered by doing it themselves and sometimes they even pass on some great ideas that we didn't think about! Like the third and middle leg of this panel design, for example, came from a customer going a little off book. We loved it so much we implemented it into our product line. 

What can be a bit daunting though, is having to go to the store and make sure you get everything you need and make sure you get the right things you need. This is where we come in. We have a couple of DIY options for anyone who wants to build their own Portable Horse Corral, but would prefer it come to their doorstep in a convenient kit. 

DIY OPTION 1: "U-DO Kit"
For those who still prefer to go to the store and collect the things you need, but want to make the corral with the Furniture Grade PVC Fittings in order to avoid having to do a lot of painting and maintenance, we offer the "U-DO Kit." This contains only what you want it to. You choose the amount of panels you want to build and we send you the amount of fittings you need to build them. You can also add glue, straps and other accessories if you like as well, but you don't have to. You can grab that stuff at the store when you go to get your pipe. The best part of the "U-DO Kit" is that it comes with a full-detailed and illustrated set of instructions that tell you everything you need to know and do in order to build your own Portable Horse Corral. If that sounds right up your alley, then click  HERE  to get yours now!

DIY OPTION 2: "Honey-Do Box Set"
For anyone who still wants to build their own Portable Horse Corral but does not want to have to leave their house to get anything, then our "Honey-Do Box Set" is perfect for you! This is our complete DIY kit. It comes with everything you need to build your own corral. It comes with all the Furniture Grade PVC fittings, pre-measured and pre-cut Utility Grade PVC pipe, Glue, Bungees, Full detailed & illustrated assembly instructions AND access to our video tutorials to further help you assemble, set up and secure your Portable Horse Corral. If this sounds like the DIY option for you, then click HERE to get yours now!

NON-DIY OPTION:
Finally, for anyone who really likes this Portable Horse Corral design but doesn't want to build it themselves and just wants to open a box and go, then our "Fully Assembled" sets are perfect for you. The panels will come to you fully assembled and ready to go! If this sounds more like you, then click HERE to get yours now!